August 2021 Volume 3

MATERIALS

Graphite’s high heat resistance, relatively low cost compared to similar substances, and excellent lubricating structure make it the perfect and sometimes only choice for metal forming applications. No other substance or mixture of substances has the same properties as graphite at a similar cost. While there has been extensive research to find a “cleaner” replacement for graphite, no substance has had significant success in all aspects of demanding jobs. However, for less demanding applications, a synthetic lubricant may be a good choice. The use of synthetic metal forming lubricants began in the late 1970s, and the majority of these lubricants started with a similar chemical makeup. They may consist of a combination of any of the following: soluble salts of organic acids; binders; wetting agents; and modifying agents to change their film properties, including polymers. Not all synthetics contain all of these ingredients, but they generally will follow this pattern. While synthetics don’t hold up to extreme metal-over-metal sliding the way graphite does, there are some significant advantages to be found by using a synthetic lubricant. Synthetic lubricants are generally considered cleaner than graphite-based lubricants and are clear liquid solutions rather than black particle dispersions like graphite-in-water products.They don’t transfer to everything they contact like a graphite-based lube does. Synthetic residues tend to stay local to a small area around the press and not blown around the plant. They will wash out of clothes and off other materials much more readily. They tend to be much more

stable than graphite-in-water formulas since synthetics are solutions rather than dispersions. Finally, synthetic residue and dusts are not electrically conductive like graphite residues. While graphite may be messier, its properties make it the clear choice for demanding applications because of its layered structure. Graphite’s material properties enable it to overcome obstacles in extreme metal-over-metal flow, high temperatures, high pressures, and precision forming. So next time you’re wondering why your shop is still using a graphite-based lubricant, remember the answer: Because it works! ■

Bob Hartsough Vice President AML Industries Email: bhartsough@amlube.com

Frank Sobnosky Chemical Engineer AML Industries Email: fsobnosky@amlube.com

FIA MAGAZINE | AUGUST 2021 43